U.S.

Department
Advisory
of Transportation
Federal Aviation
Administration Circular
Subject: Development of Date: 8/3/11 AC No: 65-33
Training/Qualification Programs for
Initiated by: AFS-320 Change:
Composite Maintenance Technicians

1. PURPOSE. This document is intended as a guideline for organizations to develop a formal

training program for qualification of composite technicians. This advisory circular (AC) contains
recommendations for the experience, training, qualification, and examination of persons
performing maintenance and repair of aircraft composite structures or other aviation composite
components. It recommends criteria for the qualification of personnel to be able to understand
the technical principles involved in the maintenance and repair of aircraft composites. This
document applies to those individuals directly responsible for providing training, supervision, or
oversight of composite maintenance personnel. Organizations may use the information contained
in this AC to develop a written program describing the guidelines used to train and qualify
personnel. This AC provides a means, but not the only means, of developing a composite
maintenance training program.

2. RELATED TITLE 14 OF THE CODE OF FEDERAL REGULATIONS (14 CFR)

PARTS.

Part 121, 121.375;

Part 145, 145.163; and
Part 147.

3. RELATED READING MATERIAL (current editions).

AC 20-107, Composite Aircraft Structure.

DOT/FAA/AR-09/0, Regional Laboratory Development Composite Maintenance
Education, Including Repair Manual, (Dec. 2009).
Society of Automotive Engineers (SAE) Aerospace, AIR5719, Teaching Points for
Awareness Class on Critical Issues in Composite Maintenance and Repair.

4. BACKGROUND. The use of composites in aircraft structures and other components has
increased fuel savings by reducing weight without sacrificing structural strength. These
characteristics are vital to meeting the demands of the aerospace industry. Additional properties
such as fatigue and corrosion resistance provide expanded design capabilities.

a. Composite Maintenance and Repair. The maintenance and repair of composites is

complex and requires knowledge and skills to assure the continued airworthiness of these
products. Practical experience is also vital for proper processing and repair of composite
structures. Experience, classroom training, hands-on on-the-job training (OJT), and assessments
AC 65-33 8/3/11

b. Composite Maintenance Training. As more composite aircraft enter into operation,

detailed and documented composite training should be developed to ensure that personnel
performing composite maintenance on aircraft structures and components properly repair
damage to meet the highest level of safety. Continual emphasis on training program development
is essential to keep pace with the changing aerospace industry needs. A detailed and
well-developed composite maintenance training program is essential for the continued
airworthiness of these products.

5. DISCUSSION. To assure that only qualified persons perform composite maintenance, an

organization should develop a written training/qualification program.

a. Training and Qualification Programs. The program should include, at a minimum, the
following elements:

Course training curriculum (see sample in Appendix 1),

Classroom/written tests,
Demonstrations, and
Hands-on training/practical tests.

b. Records and Documentation. An organizations records should include a description of

the training required for each qualified individual. Identification of those responsible for
developing, administering, and maintaining the organizations qualification program should also
be recorded.

c. Recurrent Training. A training program should include provisions for recurrent training
to continually update persons on technology, materials, and other changes regarding composite
maintenance and repair. Records of recurrent training should be maintained by the organization
and the individual.

6. PERSONNEL QUALIFICATIONS.

a. Control and Administration Program. The organization should establish a written

program for the control and administration of personnel training, examination, qualification, and
documentation. This should include a method for maintaining proficiency, including recurrent
training and steps to retrain or requalify, as required.

b. Training Instructors. The organization should provide qualified instructors. Such

individuals should have demonstrated practical experience and knowledge of composite
maintenance and repair practices. At the option of the organization, and as provided in their
written practice, an outside agency may be engaged to provide composite training and testing.

c. Instructor Qualifications. An individual should be qualified and designated, in

accordance with this AC, to provide classroom or laboratory training for composite personnel.
The instructor should:

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8/3/11 AC 65-33

(1) Have the necessary skills and knowledge to plan, organize, and present classroom,
laboratory, or OJT programs of instruction in accordance with course outlines in the method for
which he or she is qualified.

(2) Be thoroughly familiar with the theory and practical applications of the method as
utilized by the organization.

(3) Not conduct composite inspections for the acceptance of parts unless he or she is
properly qualified.

d. Formal Training. Qualified personnel should have completed sufficient formal training
to become familiar with principles and practices of applicable repair methods. The training
program should include instructions in basic principles, products, equipment, operating
procedures, and test techniques that the individual might encounter in his or her work
assignment.

e. Qualification. Qualification of personnel should be based on demonstration of

satisfactory performance as determined by the assessments outlined in paragraph 7.

7. ASSESSMENTS. A qualified person should satisfy all of the following criteria applicable to
composite maintenance and repair.

a. General Knowledge Assessment. The general knowledge assessment may be an

open-book test consisting of questions that cover the basic knowledge of composite repair
methods, materials, and procedures. In addition, questions should also cover the repair data,
workshop procedures, quality control (QC) requirements, and other aspects of company practice
that apply to the composite repair workshop.

(1) The assessment should contain a sufficient number of questions to represent a fair
distribution across the subject areas. These may be multiple-choice or short answer, or a
combination of both.

(2) A passing score of 80 percent and mandatory correction to 100, shown by 80/100
or 90/100, should be required for written assessment. In other words, failed questions must be
reviewed with all students by the instructor in class.

b. Practical Assessment. Documentation is required to show the person can:

(1) Satisfactorily demonstrate that he or she is familiar with, and can operate, the
necessary equipment and interpret FAA-accepted or FAA-approved data.

(2) Handle the materials and products correctly in accordance with safety and quality
requirements.

(3) Identify the fabric tracers, direction of the warp and fill, and yarn count.

(4) Prepare the components damaged area for repair in accordance with the
approved/accepted data.

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AC 65-33 8/3/11

(5) Lay up the repair in proper orientation and apply the cure process in accordance with
the approved/accepted data.

(6) Assess the integrity of the complete repair in accordance with the approved/accepted
data.

8. Recognition of Prior Experience. Prior experience should be considered, provided the

person presents documented evidence of training and experience acceptable to the organization.
All accepted documentation supporting recognition of prior training and experience will be
annotated in the employees training file.

9. Continued Competence. Composite repair personnel should demonstrate continued

competence every 2 years by performing a repair or by performing a practical assessment under
the direct supervision of an examiner authorized and designated by the organization or by having
participated in or performed at least six composite repairs in the 2-year period.

NOTE: In the event of unsatisfactory performance, retraining and

reassessment of the technician is required.

for
John M. Allen
Director, Flight Standards Service

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8/3/11 AC 65-33
Appendix 1
APPENDIX 1. SAMPLE COURSE CURRICULUM

NOTE: This is a sample curriculum that may be modified to meet the needs
and complexity of an organization.

SAMPLE COURSE CURRICULUM

BASIC KNOWLEDGE OF COMPOSITE TECHNOLOGY

Basic knowledge content provides a basis for composite training. Persons must be familiar with
the terminology and basics of composite technology to fully appreciate and understand critical
issues in composite maintenance and repair. Understanding the basics of this technology, having
an elementary familiarity with composite maintenance, and being aware of other important
issues is critical to further study in the course.

1. Objective: Understand the Basics of Composite Materials Technology. The person

should be able to:

a. Distinguish among adhesive, resin, fiber, and core (honey-comb, foam, corrugated,
and balsa) applications and uses.
b. Describe various composite processing parameters.
c. Describe composite material properties, failure modes, and effects of processing.
d. Describe various machining, assembly, and finishing processes.
e. Describe stiffened laminate and sandwich applications, and structural properties.

2. Objective: Understand the Basics of Composite Materials Maintenance and Repair. The
person should be able to:

a. List the basic steps in maintenance procedures from damage detection through repair
completion.
b. List key composite and expendable materials needed for a simple laminate structural
repair, including the storage requirements.
c. List the necessary tooling and equipment to accomplish a simple laminate structural
repair.
d. Understand personnel and safety equipment requirements.
e. Describe the differences between repairing composite and metal bonded structure,
including discussions on the special issues related to composite and metal bonding.
f. Discuss the importance of approved or accepted data, methods, and procedures used in
product-specific composite maintenance and repair.
g. Describe critical safety aspects of repair design, process planning, and approval.
h. Describe the steps in composite damage detection, inspection, and repair processes.
i. List basic nondestructive inspection (NDI) or Nondestructive Testing (NDT)
(Visual, Tap Test, Ultrasonic Inspection (A-Scan, C-Scan), X-Ray, Thermal Imaging) methods
used for damage assessment and post-repair inspection.

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AC 65-33 8/3/11
Appendix 1
3. Objective: Understand Other Critical Elements of Composite Maintenance and Repair.
The person should be able to:

a. Discuss basic issues affecting the selection of repairs.

b. Describe various electrical requirements and effects, including prevention of corrosion,
hazards of electromagnetic interference (EMI), electromagnetic shielding (EMS)/electromagnetic
field (EMF), and electrostatic discharge (lightning protection systems), and how they need to be
considered during repair processing.
c. Understand the need for protective coatings and surface finishing steps used for
composite aircraft maintenance.
d. Describe typical paint and surface layer removal techniques for composite parts.
e. Know the issues related to proper disposal of waste from the composite repair process.
f. Know personal skill limits and where to receive assistance during maintenancethis is
essential.
g. Discuss the importance of documenting and sharing information about damage scenarios
discovered in service between the Original Equipment Manufacturer (OEM), Maintenance
Repair Organizations (MRO), and regulators.

4. Objective: Knowledge of Composite Maintenance Research and Industry

Developments. The person should be aware of:

a. The special skill requirements of composite maintenance and repair.

b. The differences in quality control (QC) processes for bonded and bolted repairs.
c. Damage and repair inspection technologies, such as bond testing, moisture meters, and
interferometer (three-dimensional characterization).
d. The need for a repair and approval to meet regulatory requirements.

5. Objective: Understand Roles and Responsibilities. The person should:

a. Be aware of the vital interface between personnel trained in composites and personnel
that may be unaware of a need for damage disposition, such as flightcrew members, operations
staff, and line maintenance personnel.
b. Distinguish between the skills needed for structural engineers, inspectors, and technicians
dealing with composite maintenance and repair.

6. Objective: Identify and Describe Information in Required Documentation. The person

should:

a. Identify documents used in composite maintenance and repair, including those describing
acceptable field disposition procedures and the associated regulatory rules that must be followed.
b. Identify limits on the damages and repairs.
c. Describe requirements in material and process specifications and in approved repair
information.
d. Demonstrate the use of approved Structural Repair Manuals (SRM) or other approved
OEM repair documents.
e. Describe the requirements and engineering approvals necessary for valid sources of
technical information and maintenance instructions.

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Appendix 1
f. Describe the regulatory considerations for damages not covered by approved SRMs or
other approved OEM repair documents.

7. Objective: Describe Safe Handing of Advanced Composite Materials. The person should
describe procedures for safe handling of advanced composite repair materials.

INSPECTION, DAMAGE DETECTION, AND CHARACTERIZATION

This section of the class is intended to familiarize persons with the typical types of composite
damage, characteristics of the damages, and appropriate inspection procedures. It integrates
technical information and labs to ensure that persons understand what causes damage in
composite materials and the inspection methods needed for detection and complete damage
characterization.

1. Objective: Recognize Composite Damage Types and Sources. The person should be able
to:

a. Identify sources and characteristics of damage of composite sandwich- and

laminate-stiffened structures.
b. Describe damage types and their significance to structural integrity.
c. Understand the information and analysis necessary for repair design and process
development and substantiation.
d. Distinguish differences in repair procedures for damages not covered by approved SRMs
or other approved OEM repair documents.

2. Objective: Describe Composite Inspection Procedures. The person should:

a. Describe NDI/NDT techniques currently available, including an assessment of their

strengths and weaknesses.
b. Describe the critical steps necessary for inspecting a completed bonded repair, including
NDI/NDT procedures and interpretation of the results.
c. Describe various damage assessments, including visual inspection, tap test, and ultrasonic
pulse echo inspection.
d. Describe various post-repair acceptance inspections, including visual inspection, tap test,
and ultrasonic pulse echo inspection.

COMPOSITE REPAIR PROCESSES

Additional training is necessary to develop specific skills and perform tasks on the structural
components of a given aircraft type that has unique repair design, process, and inspection details.
Inspectors and others involved in repair, planning, and inspection also need the basic composite
training provided by this section of the course as a basis for future study.

1. Objective: Describe Composite Laminate Fabrication and Bonded Repair Methods. The
person should:

a. Understand the basics of composite laminate fabrication.

b. Describe the key characteristics and processing parameters for laminate fabrication.

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Appendix 1
c. Understand the basics of composite bonded repair.
d. Describe the detailed processing steps necessary for approved bonded repair.
e. Identify typical processing defects that occur in composite laminate fabrication and
bonded repair.

2. Objective: Perform a Simple Bonded Composite Repair. The person should:

a. Demonstrate and apply common drying and surface preparation techniques, including
how to inspect for acceptability.
b. Demonstrate and apply material layup and compaction processes for a simple laminate
panel repair.
c. Demonstrate how to prepare and cure a simple bonded repair to a laminate panel and
explain the types of errors to avoid.
d. Prepare a bonded repair for cure, including bagging and heating apparatus and cure.
e. Describe process parameters that affect bonded repair quality and in-process controls
necessary to avoid defects.

3. Objective: Describe Composite Laminate Bolted Assembly and Repair Methods. The
person should:

a. Describe the basics of composite bolted structural repairs.

b. Know the differences between drilling and cutting composites and metals.
c. Describe process parameters, which effect bolted composite repair quality, and in-process
controls necessary to avoid defects.
d. Describe common damage removal, surface preparation, and drilling and fastening
techniques used for bolted composite repairs, and how to inspect the repairs for acceptability.
e. Describe correct fastener selection, inspection of drilled holes, and proper fastener
installation for bolted composite repair.
f. Perform a structural laminate panel bonded repair in accordance with the SRM- or
OEM-approved repair processes.

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